EP2280919B1 - Method for producing acrolein by means of dehydration of glycerol - Google Patents

Method for producing acrolein by means of dehydration of glycerol Download PDF

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Publication number
EP2280919B1
EP2280919B1 EP09769505.0A EP09769505A EP2280919B1 EP 2280919 B1 EP2280919 B1 EP 2280919B1 EP 09769505 A EP09769505 A EP 09769505A EP 2280919 B1 EP2280919 B1 EP 2280919B1
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catalyst
reaction
glycerol
acrolein
dehydration
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German (de)
French (fr)
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EP2280919A2 (en
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Jean-Luc Dubois
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Arkema France SA
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Arkema France SA
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    • CCHEMISTRY; METALLURGY
    • C07ORGANIC CHEMISTRY
    • C07CACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C45/00Preparation of compounds having >C = O groups bound only to carbon or hydrogen atoms; Preparation of chelates of such compounds
    • C07C45/51Preparation of compounds having >C = O groups bound only to carbon or hydrogen atoms; Preparation of chelates of such compounds by pyrolysis, rearrangement or decomposition
    • C07C45/52Preparation of compounds having >C = O groups bound only to carbon or hydrogen atoms; Preparation of chelates of such compounds by pyrolysis, rearrangement or decomposition by dehydration and rearrangement involving two hydroxy groups in the same molecule

Definitions

  • the present invention relates to an improved process for producing acrolein by dehydration of glycerol in the presence of acid gas additives.
  • Acrolein is the simplest unsaturated aldehyde. It is also called 2-propenal, acrylaldehyde or acrylic aldehyde. By its structure, acrolein has a high reactive power through the presence of its two reactive functions that are likely to react individually or together. This is why acrolein has many applications, especially as a synthesis intermediate. In particular, it is a key intermediate for the synthesis of methionine, the synthetic amino acid used as a supplement to animal feed, which has become a substitute for fishmeal.
  • Acrolein is a non-isolated synthesis intermediate of acrylic acid in the industrial production of acrylic acid by catalytic oxidation of propylene in the gas phase.
  • Acrolein is also reacted with methyl vinyl ether and then hydrolyzed with glutaraldehyde, which has many uses in leather tanning, as a biocide in oil drilling and in the processing of cutting oils, and as a chemical disinfectant and sterilant for hospital equipment.
  • the most commonly used acrolein production method is based on the catalytic gas phase oxidation reaction of propylene with oxygen in the air.
  • the acrolein thus obtained can then be directly integrated into a process for the manufacture of acrylic acid.
  • a purification section makes it possible to eliminate the by-products of the reaction. mainly carbon oxides, acrylic acid, acetic acid and acetaldehyde.
  • acrolein is therefore highly dependent on the propylene raw material obtained by steam cracking or catalytic cracking of petroleum fractions.
  • This raw material of fossil origin, contributes, moreover, to the increase of the greenhouse effect. It therefore appears necessary to have a process for the synthesis of acrolein that is not dependent on the propylene resource and that uses another, preferably renewable, raw material.
  • This process would be particularly advantageous for the synthesis of methionine and other products, which could then be called "obtained from biomass". Indeed, methionine when it is used in animal feed is metabolized rapidly and the carbon dioxide that is found in the atmosphere contributes to the increase of the greenhouse effect.
  • Glycerol also called glycerin when it is in the form of aqueous solution
  • methyl esters which are themselves used in particular as fuels or fuels in diesel and fuel oil. domesticated. It is a natural product, available in large quantities, it can be stored and transported without difficulty. It has the advantage of being a renewable raw material meeting the criteria associated with the new concept of "green chemistry".
  • This reaction is a balanced reaction; as a rule the hydration reaction is favored at low temperatures, and dehydration is favored at high temperatures. To obtain acrolein, it is therefore necessary to implement a sufficient temperature, and / or a partial vacuum to move the reaction.
  • the reaction can be carried out in the liquid phase or in the gas phase. This type of reaction is known to be catalyzed by acids.
  • acrolein is obtained by passing glycerol vapors at a sufficiently high temperature over acid salts having at least three acidic functions such as, for example, phosphoric acid salts.
  • the yields indicated are greater than 75% after fractional distillation.
  • the Chinese patent application CN 1394839 relates to a process for preparing 3-hydroxypropanaldehyde from glycerol.
  • the acrolein an intermediate product of the reaction, is obtained by passing pure glycerol vaporized on a potassium sulfate or magnesium sulfate catalyst, and then the acrolein obtained is rehydrated to hydroxypropanaldehyde. The yields of the reaction are not given.
  • the patent US5,387,720 describes a process for the production of acrolein by dehydration of glycerol, in the liquid phase or in the gas phase, on acidic solid catalysts defined by their Hammett acidity.
  • the catalysts must have a Hammett acidity of less than +2 and preferably less than -3.
  • These catalysts correspond for example to natural or synthetic siliceous materials, such as mordenite, montmorillonite, acidic zeolites; supports, such as oxides or siliceous materials, for example alumina (Al 2 O 3 ), titanium oxide (TiO 2 ), coated with inorganic acids, mono, di or triacids; oxides or mixed oxides such as gamma alumina, mixed oxide ZnO-Al 2 O 3 , or heteropolyacids.
  • an aqueous solution comprising from 10 to 40% of glycerol is used and is carried out at temperatures of between 180 ° and 340 ° C in the liquid phase and between 250 ° and 340 ° C in the gas phase.
  • the reaction in the gas phase is preferable because it makes it possible to have a glycerol conversion rate close to 100%, which leads to an aqueous solution of acrolein containing by-products.
  • About 10% of the glycerol is converted to hydroxypropanone, which is found as a major by-product in the acrolein solution.
  • Acrolein is recovered and purified by distillation or fractional condensation.
  • a conversion limited to 15-25% is sought to avoid an excessive loss of selectivity.
  • the patent US 5,426,249 describes the same gas phase dehydration process of glycerol to acrolein, but followed by hydration of acrolein and hydrogenation to lead to 1,2- and 1,3-propane diol.
  • the dehydration reaction of glycerol to acrolein is thus generally accompanied by side reactions resulting in the formation of by-products such as hydroxypropanone, propanaldehyde, acetaldehyde, acetone, acrolein adducts on glycerol (called acetals), polycondensation products of glycerol, cyclic glycerol ethers ..., but also phenol and polyaromatic compounds which are at the origin of the formation of glycerol. coke on the catalyst. This results, on the one hand, in a reduction of the yield and in the selectivity of acrolein, on the other hand a deactivation of the catalyst.
  • inert gases which by definition do not contribute to the reaction, involves the use of a large reactor, compared to what is necessary for the reagents only. This entails an additional cost. This is the reason why the applicant company has continued its work to improve the acrolein selectivity of the reaction by focusing on the conditions of effectiveness and / or selectivity of the catalysts already known to be used for the synthesis of the acrolein from glycerol.
  • the aim of the present invention is to overcome these disadvantages by implementing the method by adding to the gaseous reaction medium a compound capable of being fixed, at least temporarily, to these sites and inhibiting them during the process to avoid the formation of by-products.
  • the present invention relates to a process for the synthesis of acrolein by dehydration of glycerol in the presence of a solid acid catalyst characterized in that it is carried out in a reaction medium comprising a gaseous phase containing an acidic compound.
  • the term "acid compound” is intended to mean a compound which, in addition to what will be specified below, will have a pKa of less than 6.3 in solution in water.
  • CO 2 is not an acid within the meaning of the present invention.
  • the dehydration reaction is carried out, for example, on acidic solid catalysts such as those described in the French patent. FR 2,882,052 .
  • Suitable catalysts are homogeneous or multiphase materials which are insoluble in the reaction medium and which have a Hammett acidity, denoted H 0 of less than +2.
  • H 0 Hammett acidity
  • the catalysts meeting the acidity criterion H 0 of less than +2 may be chosen from natural or synthetic siliceous materials or acidic zeolites; inorganic carriers, such as oxides, coated with inorganic acids, mono, di, tri or polyacids; oxides or mixed oxides, iron phosphates or heteropolyacids.
  • the catalysts are chosen from zeolites, Nafion® composites (acid-based sulfonic fluorinated polymers), chlorinated aluminas, phospho or silico-tungstic and / or silicotungstic acids and salts, and various metal oxide solids such as tantalum oxide Ta 2 O 5 , niobium oxide Nb 2 O 5 , alumina Al 2 O 3 , titanium oxide TiO 2 , zirconia ZrO 2 , tin oxide SnO 2 , silica SiO 2 or silicoaluminate SiO 2 Al 2 O 3 , impregnated with acidic functions such as borate BO 3 , sulfate SO 4 , WO 3 tungstate, PO 4 phosphate, SiO 2 silicate, or MoO 3 molybdate. According to the data of the literature, these catalysts all have a Hammett acidity H 0 of less than +2.
  • the preferred catalysts are sulphated zirconias, zirconium phosphates, tungsten zirconias, silicified zirconias, sulphated titanium or tin oxides, phosphated aluminas or silicas, doped iron phosphates, phospho or silico acid salts. -tungstics.
  • the catalysts selected for this reaction are acidic solids.
  • the acidity of solids can be measured in many ways and Hammett's method is just one of them.
  • Aline Auroux's publications describe different methods of measuring solids acidity scales such as: A. Auroux and A. Gervasini, "J. Microcalorimetric Study of the Acidity and Basicity of Metal Oxide Surfaces” Phys. Chem., (1990) 94, 6371-79 and L. Damjanovic and A. Auroux, in Handbook of Thermal Analysis and Calorimetry, Vol 5, Chapter 11 pages 387-485: Recent Advances, Techniques and Applications, ME Brown and PK Gallager, editors (2008 Elsevier BV ).
  • the process is carried out in the presence of an acidic compound present in the gaseous phase of the reaction medium and which has an affinity with the basic undesirable sites constituting the catalyst.
  • This compound will be selected from hard and soft acids as defined in the so-called Pearson classification. in the following articles: RG Pearson, J. Am. Chem. Soc., 85, 3533 (1963) ); RG Pearson, Science, 151 (1966) 172 ; RG Pearson, Chemistry in England, March 1967, 103 ; RG Pearson, J. Chemical Education, Vol 45 No. 9 (1968) 581 and Vol 45 No. 10 (1968) 643 ; RG Parr and RG Pearson, J. Am. Chem. Soc., (1983) 105, 7512 .
  • These compounds can be gaseous under normal conditions but they can be either liquid or even solid if they are likely to pass, under the operating conditions of the process, into the gaseous phase of the reaction medium.
  • the dehydration is conducted in the presence of a gaseous phase containing a minor fraction of at least one acid compound as defined by Pearson's classification.
  • This acidic compound will be chosen especially from SO 3 , SO 2 , NO 2 , etc. It would not be outside the scope of the invention, if a mixture of these compounds is used. According to Pearson's theory hard acids prefer to associate with hard bases and soft acids with moles. A mixture of compounds combining different acidities can be used to inhibit the various basic sites present on the catalyst.
  • the content of acidic compounds will depend on the nature of the catalyst chosen for the dehydration reaction. It will generally be between 1 and 3000 ppm of the gaseous phase or expressed in percentages by volume of 0.0001 to 0.3%.
  • the acidic compound may be in liquid or even solid form if it is capable under reaction conditions of passing into the liquid phase to reach the above contents or, in the case of a solid compound , solubilize and then move to the liquid phase as has been specified above.
  • patent EP 1 253 132 discloses the use in a process for synthesizing acrylic acid by oxidation of alkanes or acrolein in the presence of a reducing compound consisting of organic acids (formic or oxalic acid) or compounds containing sulfur such as SO 2 or H 2 S, SO 2 being preferred.
  • a reducing compound consisting of organic acids (formic or oxalic acid) or compounds containing sulfur such as SO 2 or H 2 S, SO 2 being preferred.
  • SO 2 sulfur
  • the reaction according to the invention can be carried out in the gas phase or in the liquid phase, preferably in the gas phase.
  • the catalyst can be ex situ, for example by extraction of the catalyst and combustion in air or with a gaseous mixture containing molecular oxygen.
  • the temperature and pressure at which the regeneration is effected need not be the same as those at which the reaction is carried out.
  • the addition of the acidic compounds in the sense of Pearson, is performed at the Reactor and not during the regeneration.
  • the process of the invention can be carried out continuously in situ, at the same time as the reaction taking into account the presence of a small amount of molecular oxygen or a gas containing molecular oxygen in the reactor.
  • the regeneration is similar to an inhibition of the deactivation and is done at the temperature and pressure of the reaction. Because of these particular conditions where the regeneration takes place continuously, the injection of the gaseous acid compound is found to be simultaneous and preferably upstream of the catalytic bed so that the acidic compounds are perfectly mixed in the reaction mixture.
  • the catalyst circulates in two capacities, a reactor and a regenerator. It is known that the dehydration reaction is endothermic, so it is necessary to bring energy to the first capacity, while the regeneration consisting of the combustion of the coke is exothermic, it is necessary to extract calories from the second capacity.
  • the two systems can be compensated: according to the process of the invention, the regeneration of the catalyst under an oxygen flow by combustion leads to a heating of the catalyst and consequently provides the energy necessary for the dehydration reaction when the heated catalyst returns to the reactor.
  • the residence time in each capacity depends on the deactivation rate of the catalyst and the coke rate formed on the catalyst. Indeed, a minimum coke rate is desirable to bring the solid back to the correct temperature, and a maximum coke rate is necessary to avoid degrading the solid by sintering during combustion.
  • the injection of the gaseous acid compound is preferably carried out at the reactor.
  • the dehydration reaction is carried out in the gas phase in the presence of a catalyst at a temperature ranging from 150 ° C. to 500 ° C., preferably between 250 ° C. and 350 ° C., and a pressure of between 1 and 5 bar.
  • a catalyst at a temperature ranging from 150 ° C. to 500 ° C., preferably between 250 ° C. and 350 ° C., and a pressure greater than 5 bar and preferably comprised between between 20 and 80 bars.
  • acrolein When dehydrating glycerol in the presence of a conventional acidic catalyst is obtained acrolein but also by-products, such as hydroxypropanone, propanaldehyde, acetaldehyde, acetone, phenol, the products of addition of acrolein to glycerol, polycondensation products of glycerol, cyclic or non-cyclic glycerol ethers.
  • the reaction can be conducted under the following conditions.
  • a Pyrex reactor containing a sintered catalyst bed is used.
  • a catalyst such as the dehydration catalyst Zirconia Tungstea from Daiichi Kigenso KK, reference Z1044 having a mass of about 6.6 g and reduced to a particle size of 0.1-0.15 mm diluted with ml of fine grain silicon carbide (0.125 mm).
  • ml of fine grain silicon carbide (0.125 mm).
  • the reactor is then placed in an oven connected to the test facility.
  • the temperature of the catalyst is regulated in temperature at 305 ° C. measured at the level of the "dehydration layer".
  • the reactor is fed from above by a gaseous mixture of Helium-Krypton / SO 2 / Water-Glycerol at a pressure of 1.3 bar absolute.
  • the Helium-Krypton gas mixture contains 4.92% Krypton which serves as internal standard.
  • the water-glycerol mixture contains 30% by weight of glycerol.
  • the rate of introduction of the charge mixture is such that the hourly volume velocity (VVH) will be 2,000 h -1 . .
  • the hourly space velocity is equal to the ratio of the total gas flow rate of the gas mixture expressed in normal liters per hour by the apparent volume of catalyst expressed in liters.
  • the effluents are trapped in the water leaving the reactor by a trap cooled to 0 ° C to separate the liquid effluents incondensables.
  • Acrolein and hydroxypropanone, as the model compound of byproducts other than acrylic acid, are determined by chromatographic analysis.
  • the effluents are accumulated in the trap for a period of 60 minutes.
  • Non-condensable gases are analyzed during the balance sheet.
  • the yield of acrolein produced is 70 mol%, and acrylic acid 2 mol% and hydroxyacetone 0.5 mol%.
  • Example 1 will be repeated, but in the absence of SO 2 .
  • the effluents are accumulated in the trap for a period of 60 minutes.
  • Non-condensable gases are analyzed during the balance sheet.
  • the yield of acrolein produced is 68 mol%, and acrylic acid 2 mol% and hydroxyacetone 2 mol%.
  • Example 2 The same Pyrex reactor is used as in Example 1. It is charged with a zirconia tungsten dehydration catalyst of Daiichi Kigenso Kagaku Kogyo reference Z1044 ring, crushed and sieved to a particle size of 0.32-0.50 mm. of volume 7 ml and mass 9.18 g. The undiluted catalyst is placed between two layers of silicon carbide.
  • a zirconia tungsten dehydration catalyst of Daiichi Kigenso Kagaku Kogyo reference Z1044 ring, crushed and sieved to a particle size of 0.32-0.50 mm. of volume 7 ml and mass 9.18 g.
  • the undiluted catalyst is placed between two layers of silicon carbide.
  • the reactor is placed in an oven which is regulated at a temperature of 275 ° C.
  • the reactor is powered by a gaseous mixture at 275 ° C N 2 / O 2 / SO 2 / water / glycerol at a pressure of 1.3 bar absolute.
  • This gaseous mixture is obtained by injecting into an electric vaporizer, on the one hand, a current of nitrogen and a stream of oxygen controlled in flow by mass flow controllers and, on the other hand, a liquid flow of a glycerol mixture (Prolabo ), demineralized water and 7.4% SO 2 (Sigma-Aldrich) sulphurous acid by an HPLC type volumetric pump whose flow is controlled by a balance.
  • the charge introduction rate of the charge mixture is such that the hourly volume velocity (VVH) is 4,200 h -1
  • a balance is made after 3 hours and after 24 hours of injection of the mixture.
  • a balance is made after 3 hours and 24 hours.

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Description

La présente invention concerne un procédé perfectionné de fabrication d'acroléine par déshydratation du glycérol en présence d'additifs gazeux acides.The present invention relates to an improved process for producing acrolein by dehydration of glycerol in the presence of acid gas additives.

L'acroléine est le plus simple des aldéhydes insaturés. On l'appelle aussi 2-propenal, acrylaldéhyde ou aldéhyde acrylique. De par sa structure, l'acroléine a un pouvoir réactif élevé grâce à la présence de ses deux fonctions réactives qui sont susceptibles de réagir individuellement ou ensemble. C'est pourquoi, l'acroléine trouve de nombreuses applications, notamment comme intermédiaire de synthèse. C'est en particulier un intermédiaire clé pour la synthèse de la méthionine, acide aminé de synthèse utilisée comme complément de l'alimentation animale qui s'est imposé comme substitut des farines de poisson. L'acroléine est un intermédiaire de synthèse non isolé de l'acide acrylique dans la production industrielle de l'acide acrylique par oxydation catalytique du propylène en phase gazeuse. On connaît l'importance de la chimie de l'acide acrylique et de ses dérivés. L'acroléine conduit aussi par réaction avec le méthyl vinyl éther puis hydrolyse, au glutaraldéhyde qui possède de nombreuses utilisations dans le tannage du cuir, comme biocide dans les forages pétroliers et lors du traitement des huiles de coupe, et comme désinfectant et stérilisant chimique pour le matériel hospitalier.Acrolein is the simplest unsaturated aldehyde. It is also called 2-propenal, acrylaldehyde or acrylic aldehyde. By its structure, acrolein has a high reactive power through the presence of its two reactive functions that are likely to react individually or together. This is why acrolein has many applications, especially as a synthesis intermediate. In particular, it is a key intermediate for the synthesis of methionine, the synthetic amino acid used as a supplement to animal feed, which has become a substitute for fishmeal. Acrolein is a non-isolated synthesis intermediate of acrylic acid in the industrial production of acrylic acid by catalytic oxidation of propylene in the gas phase. The importance of the chemistry of acrylic acid and its derivatives is well known. Acrolein is also reacted with methyl vinyl ether and then hydrolyzed with glutaraldehyde, which has many uses in leather tanning, as a biocide in oil drilling and in the processing of cutting oils, and as a chemical disinfectant and sterilant for hospital equipment.

Le procédé de production d'acroléine le plus communément utilisé est basé sur la réaction d'oxydation catalytique en phase gazeuse du propylène par l'oxygène de l'air. L'acroléine ainsi obtenue peut alors être directement intégrée dans un procédé de fabrication d'acide acrylique. Lorsque l'acroléine sert de matière première pour la synthèse de la méthionine et/ou d'acide acrylique et/ou d'acrylonitrile ou pour des réactions de chimie fine, une section de purification permet d'éliminer les sous-produits de la réaction, principalement les oxydes de carbone, l'acide acrylique, l'acide acétique et l'acétaldéhyde.The most commonly used acrolein production method is based on the catalytic gas phase oxidation reaction of propylene with oxygen in the air. The acrolein thus obtained can then be directly integrated into a process for the manufacture of acrylic acid. When acrolein is used as a raw material for the synthesis of methionine and / or acrylic acid and / or acrylonitrile or for fine chemical reactions, a purification section makes it possible to eliminate the by-products of the reaction. mainly carbon oxides, acrylic acid, acetic acid and acetaldehyde.

La production d'acroléine est donc fortement dépendante de la matière première propylène obtenu par vapocraquage ou craquage catalytique de coupes pétrolières. Cette matière première, d'origine fossile, contribue de plus, à l'augmentation de l'effet de serre. Il apparaît donc nécessaire de disposer d'un procédé de synthèse d'acroléine non dépendant de la ressource en propylène et utilisant une autre matière première, de préférence renouvelable. Ce procédé serait particulièrement avantageux pour la synthèse de la méthionine et autres produits, qui pourrait alors être dite "obtenue à partir de biomasse". En effet, la méthionine lors de son utilisation dans l'alimentation animale, est métabolisée rapidement et le gaz carbonique qui se retrouve dans l'atmosphère contribue à l'augmentation de l'effet de serre. Si l'acroléine est obtenue à partir d'une matière première renouvelable, obtenue par exemple à partir d'huile végétale, les émissions de CO2 n'entrent plus dans le bilan du procédé, car elles compensent le gaz carbonique utilisé par la biomasse pour sa croissance ; il n'y a donc pas d'augmentation de l'effet de serre. Un tel procédé répond alors aux critères associés au nouveau concept de "chimie verte" dans un cadre plus global de développement durable.The production of acrolein is therefore highly dependent on the propylene raw material obtained by steam cracking or catalytic cracking of petroleum fractions. This raw material, of fossil origin, contributes, moreover, to the increase of the greenhouse effect. It therefore appears necessary to have a process for the synthesis of acrolein that is not dependent on the propylene resource and that uses another, preferably renewable, raw material. This process would be particularly advantageous for the synthesis of methionine and other products, which could then be called "obtained from biomass". Indeed, methionine when it is used in animal feed is metabolized rapidly and the carbon dioxide that is found in the atmosphere contributes to the increase of the greenhouse effect. If acrolein is obtained from a renewable raw material, obtained for example from vegetable oil, CO 2 emissions no longer enter the balance sheet of the process, because they offset the carbon dioxide used by biomass for its growth; there is no increase in the greenhouse effect. Such a process then meets the criteria associated with the new concept of "green chemistry" in a more global framework of sustainable development.

11 est également connu de synthétiser des aldéhydes tels que l'acroléine par déshydratation d'un polyalcool tel que le glycérol. Le glycérol (appelé aussi glycérine quand il est sous forme de solution aqueuse) est notamment issu de la méthanolyse des huiles végétales et animales en même temps que les esters méthyliques qui sont, eux, employés notamment comme carburants ou combustibles dans le gazole et le fioul domestique. C'est un produit naturel, disponible en grande quantité, il peut être stocké et transporté sans difficulté. Il présente l'intérêt d'être une matière première renouvelable répondant aux critères associés au nouveau concept de "chimie verte".It is also known to synthesize aldehydes such as acrolein by dehydration of a polyhydric alcohol such as glycerol. Glycerol (also called glycerin when it is in the form of aqueous solution) is notably derived from the methanolysis of vegetable and animal oils at the same time as the methyl esters, which are themselves used in particular as fuels or fuels in diesel and fuel oil. domesticated. It is a natural product, available in large quantities, it can be stored and transported without difficulty. It has the advantage of being a renewable raw material meeting the criteria associated with the new concept of "green chemistry".

De nombreuses études récentes sont consacrées à la valorisation du glycérol et notamment à la préparation de l'acroléine. Le procédé objet de ces études met en oeuvre une réaction de déshydratation du glycérol selon les réactions consécutives :

        CH2OH-CHOH-CH2OH → CH2OH-CH2-CHO+ H2O ⇔ CH2=CH-CHO + 2H2O

qui permettent d'obtenir l'acroléine.
Many recent studies are devoted to the valorisation of glycerol and in particular to the preparation of acrolein. The process that is the subject of these studies implements a glycerol dehydration reaction according to the consecutive reactions:

CH 2 OH-CHOH-CH 2 OH → CH 2 OH-CH 2 -CHO + H 2 O CH 2 = CH-CHO + 2H 2 O

which make it possible to obtain acrolein.

Cette réaction est une réaction équilibrée ; en règle générale la réaction d'hydratation est favorisée aux basses températures, et la déshydratation est favorisée aux températures élevées. Pour obtenir l'acroléine, il faut donc mettre en oeuvre une température suffisante, et/ou un vide partiel pour déplacer la réaction. La réaction peut être effectuée en phase liquide ou en phase gaz. Ce type de réaction est connu pour être catalysée par des acides.This reaction is a balanced reaction; as a rule the hydration reaction is favored at low temperatures, and dehydration is favored at high temperatures. To obtain acrolein, it is therefore necessary to implement a sufficient temperature, and / or a partial vacuum to move the reaction. The reaction can be carried out in the liquid phase or in the gas phase. This type of reaction is known to be catalyzed by acids.

Selon le brevet FR 69.5931 , on obtient l'acroléine en faisant passer des vapeurs de glycérine à une température suffisamment haute sur des sels d'acides ayant au moins trois fonctions acides comme par exemple des sels d'acide phosphorique. Les rendements indiqués sont supérieurs à 75% après distillation fractionnée.According to the patent FR 69.5931 acrolein is obtained by passing glycerol vapors at a sufficiently high temperature over acid salts having at least three acidic functions such as, for example, phosphoric acid salts. The yields indicated are greater than 75% after fractional distillation.

Dans le brevet US 2,558,520 , la réaction de déshydratation est faite en phase gaz/liquide en présence de terres de diatomées imprégnées de sels d'acide phosphorique, en suspension dans un solvant aromatique. Un taux de conversion du glycérol en acroléine de 72,3% est obtenu dans ces conditions.In the patent US 2,558,520 the dehydration reaction is carried out in the gas / liquid phase in the presence of diatomaceous earths impregnated with phosphoric acid salts, suspended in an aromatic solvent. A conversion of glycerol to acrolein of 72.3% is obtained under these conditions.

Le procédé décrit dans la demande WO 99/05085 est basé sur une catalyse homogène complexe, sous atmosphère CO/H2 sous pression 20/40 bars et en présence d'un solvant tel qu'une solution aqueuse de sulpholane.The process described in the application WO 99/05085 is based on a complex homogeneous catalysis, under a CO / H 2 atmosphere under 20/40 bar pressure and in the presence of a solvent such as an aqueous solution of sulpholane.

La demande de brevet chinois CN 1394839 porte sur un procédé de préparation du 3-hydroxypropanaldéhyde à partir de glycérol. L'acroléine, produit intermédiaire de la réaction, est obtenue en faisant passer du glycérol pur vaporisé sur un catalyseur de type sulfate de potassium ou sulfate de magnésium, puis l'acroléine obtenue est réhydratée en hydroxypropanaldéhyde. Les rendements de la réaction ne sont pas donnés.The Chinese patent application CN 1394839 relates to a process for preparing 3-hydroxypropanaldehyde from glycerol. The acrolein, an intermediate product of the reaction, is obtained by passing pure glycerol vaporized on a potassium sulfate or magnesium sulfate catalyst, and then the acrolein obtained is rehydrated to hydroxypropanaldehyde. The yields of the reaction are not given.

Le brevet US 5,387,720 décrit un procédé de production d'acroléine par déshydratation du glycérol, en phase liquide ou en phase gaz sur des catalyseurs solides acides définis par leur acidité de Hammett. Les catalyseurs doivent avoir une acidité de Hammett inférieure à +2 et de préférence inférieure à -3. Ces catalyseurs correspondent par exemple à des matériaux siliceux naturels ou de synthèse, comme la mordénite, la montmorillonite, les zéolithes acides ; des supports, tels que des oxydes ou des matériaux siliceux, par exemple l'alumine (Al2O3), l'oxyde de titane (TiO2), recouverts par des acides inorganiques, mono, di ou triacides ; des oxydes ou oxydes mixtes tels que l'alumine gamma, l'oxyde mixte ZnO-Al2O3, ou encore des hétéropolyacides. Selon ce brevet, une solution aqueuse comprenant de 10 à 40% de glycérol est utilisée et on opère à des températures comprises entre 180° et 340°C en phase liquide et entre 250° et 340°C en phase gaz. Selon les auteurs de ce brevet, la réaction en phase gaz est préférable car elle permet d'avoir un taux de conversion du glycérol proche de 100 %, qui conduit à une solution aqueuse d'acroléine contenant des produits secondaires. Une proportion d'environ 10% du glycérol est convertie en hydroxypropanone qui se retrouve comme sous-produit majoritaire dans la solution d'acroléine. L'acroléine est récupérée et purifiée par distillation ou condensation fractionnée. Pour une réaction en phase liquide, une conversion limitée à 15 - 25 % est recherchée, pour éviter une perte trop importante de sélectivité. Le brevet US 5,426,249 décrit le même procédé en phase gaz de déshydratation du glycérol en acroléine, mais suivi d'une hydratation de l'acroléine et d'une hydrogénation pour conduire aux 1,2- et 1,3-propane diol.The patent US5,387,720 describes a process for the production of acrolein by dehydration of glycerol, in the liquid phase or in the gas phase, on acidic solid catalysts defined by their Hammett acidity. The catalysts must have a Hammett acidity of less than +2 and preferably less than -3. These catalysts correspond for example to natural or synthetic siliceous materials, such as mordenite, montmorillonite, acidic zeolites; supports, such as oxides or siliceous materials, for example alumina (Al 2 O 3 ), titanium oxide (TiO 2 ), coated with inorganic acids, mono, di or triacids; oxides or mixed oxides such as gamma alumina, mixed oxide ZnO-Al 2 O 3 , or heteropolyacids. According to this patent, an aqueous solution comprising from 10 to 40% of glycerol is used and is carried out at temperatures of between 180 ° and 340 ° C in the liquid phase and between 250 ° and 340 ° C in the gas phase. According to the authors of this patent, the reaction in the gas phase is preferable because it makes it possible to have a glycerol conversion rate close to 100%, which leads to an aqueous solution of acrolein containing by-products. About 10% of the glycerol is converted to hydroxypropanone, which is found as a major by-product in the acrolein solution. Acrolein is recovered and purified by distillation or fractional condensation. For a reaction in the liquid phase, a conversion limited to 15-25% is sought to avoid an excessive loss of selectivity. The patent US 5,426,249 describes the same gas phase dehydration process of glycerol to acrolein, but followed by hydration of acrolein and hydrogenation to lead to 1,2- and 1,3-propane diol.

La réaction de déshydratation du glycérol en acroléine s'accompagne ainsi généralement de réactions secondaires entraînant la formation de sous-produits tels que l'hydroxypropanone, le propanaldéhyde, l'acétaldéhyde, l'acétone, des produits d'addition de l'acroléine sur le glycérol (appelés acétals), des produits de polycondensation du glycérol, des éthers de glycérol cycliques..., mais aussi de phénol et des composés polyaromatiques qui sont à l'origine de la formation de coke sur le catalyseur. Il en résulte, d'une part une diminution du rendement et de la sélectivité en acroléine, d'autre part une désactivation du catalyseur. La présence des sous-produits dans l'acroléine, tels que l'hydroxypropanone ou le propanaldéhyde, certains étant de plus difficiles à isoler, nécessite des étapes de séparation et purification qui conduisent à des coûts élevés de récupération de l'acroléine purifiée. Par ailleurs, il est nécessaire de régénérer le catalyseur très souvent de façon à retrouver une activité catalytique satisfaisante.The dehydration reaction of glycerol to acrolein is thus generally accompanied by side reactions resulting in the formation of by-products such as hydroxypropanone, propanaldehyde, acetaldehyde, acetone, acrolein adducts on glycerol (called acetals), polycondensation products of glycerol, cyclic glycerol ethers ..., but also phenol and polyaromatic compounds which are at the origin of the formation of glycerol. coke on the catalyst. This results, on the one hand, in a reduction of the yield and in the selectivity of acrolein, on the other hand a deactivation of the catalyst. The presence of byproducts in acrolein, such as hydroxypropanone or propanaldehyde, some of which are more difficult to isolate, requires separation and purification steps which lead to high costs of recovery of the purified acrolein. Moreover, it is necessary to regenerate the catalyst very often so as to find a satisfactory catalytic activity.

La société déposante a cherché à résoudre ces problèmes en proposant dans le brevet français publié sous le n° 2.882.052 de conduire la réaction de déshydratation du glycérol en présence d'oxygène moléculaire. Il a été observé à cette occasion que de façon surprenante l'apport d'oxygène réduit la formation de composés aromatiques comme le phénol, et de sous-produits provenant d'une hydrogénation de produits déshydratés comme le propanaldéhyde et l'acétone, mais aussi de l'hydroxypropanone. La formation de coke sur le catalyseur se trouve réduite. Il en résulte une inhibition de la désactivation du catalyseur et une régénération en continu du catalyseur. Certains sous-produits se trouvent présents en quantités nettement plus faibles ce qui facilite les étapes ultérieures de purification.The applicant company has sought to solve these problems by proposing in French Patent No. 2,882,052 to conduct the dehydration reaction of glycerol in the presence of molecular oxygen. It has been observed on this occasion that surprisingly the supply of oxygen reduces the formation of aromatic compounds such as phenol, and by-products from a hydrogenation of dehydrated products such as propanaldehyde and acetone, but also hydroxypropanone. The formation of coke on the catalyst is reduced. This results in inhibition of catalyst deactivation and continuous regeneration of the catalyst. Some by-products are present in much smaller amounts which facilitates subsequent purification steps.

Pour intéressants qu'ils soient, ces résultats ne sont pas suffisants sur le plan économique pour passer à une échelle industrielle. D'autre part la mise en oeuvre du procédé en présence d'oxygène implique des précautions opératoires afin d'éviter qu'elle ne s'emballe par aller jusqu' à la combustion avec ses risques d'explosion. Cela entraîne par exemple l'utilisation d'un gaz inerte pour rester en dehors de la zone d'inflammabilité. L'azote de l'air peut constituer une partie de ce gaz inerte mais sera souvent en quantité insuffisante ce qui amènera à utiliser des gaz inertes additionnels tels que les gaz de recycle contenant outre l'azote qui n'a pas pu réagir, les gaz de combustion et des gaz rares comme l'Argon, mais aussi des gaz volontairement ajoutés tels que les gaz cités ci-dessus mais aussi du méthane et des alcanes légers. L'utilisation de gaz inertes et qui, par définition ne contribuent pas à la réaction, implique l'utilisation d'un réacteur de grande taille, par rapport à ce qui est nécessaire aux seuls réactifs. Ceci entraîne un surcoût. C'est la raison pour laquelle la société déposante a poursuivi ses travaux pour améliorer la sélectivité en acroléine de la réaction en se focalisant sur les conditions d'efficacité et/ou de sélectivité des catalyseurs déjà connus pour être utilisés pour la synthèse de l'acroléine à partir du glycérol.Interestingly, these results are not economically sufficient to move to an industrial scale. On the other hand the implementation of the process in the presence of oxygen involves operating precautions to prevent it from racing to go to the combustion with its risk of explosion. it for example, the use of an inert gas to stay outside the flammable zone. Nitrogen in the air may be a part of this inert gas but will often be insufficient in quantity, which will lead to the use of additional inert gases such as recycle gases containing, in addition to nitrogen, which could not react, combustion gases and rare gases such as Argon, but also voluntarily added gases such as the gases mentioned above but also methane and light alkanes. The use of inert gases, which by definition do not contribute to the reaction, involves the use of a large reactor, compared to what is necessary for the reagents only. This entails an additional cost. This is the reason why the applicant company has continued its work to improve the acrolein selectivity of the reaction by focusing on the conditions of effectiveness and / or selectivity of the catalysts already known to be used for the synthesis of the acrolein from glycerol.

La société déposante a découvert avec surprise que les catalyseurs de type acide connus pour la catalyse de la réaction de déshydratation qui sont des matériaux homogènes ou multiphases solides insolubles dans le milieu réactionnel qui, bien qu'acides, pouvaient présenter aussi certains sites indésirables vraisemblablement à l'origine de la formation des sous-produits par des mécanismes réactionnels parfois peu prévisibles.The applicant company has surprisingly discovered that acid catalysts known for the catalysis of the dehydration reaction which are homogeneous or solid multiphase materials insoluble in the reaction medium which, although acidic, could also have some undesirable sites likely to the origin of the formation of byproducts by reaction mechanisms sometimes unpredictable.

Le but de la présente invention est de pallier ces inconvénients en mettant en oeuvre le procédé en ajoutant dans le milieu gazeux réactionnel un composé susceptible de se fixer, au moins temporairement, sur ces sites et en les inhibant en cours de processus d'éviter la formation des sous-produits.The aim of the present invention is to overcome these disadvantages by implementing the method by adding to the gaseous reaction medium a compound capable of being fixed, at least temporarily, to these sites and inhibiting them during the process to avoid the formation of by-products.

La présente invention a pour objet un procédé de synthèse de l'acroléine par déshydratation du glycérol en présence d'un catalyseur acide solide caractérisé en ce qu'il est mis en oeuvre dans un milieu réactionnel comportant une phase gazeuse contenant un composé acide.The present invention relates to a process for the synthesis of acrolein by dehydration of glycerol in the presence of a solid acid catalyst characterized in that it is carried out in a reaction medium comprising a gaseous phase containing an acidic compound.

On entend par composé acide, au sens de la présente invention, un composé qui, outre ce qui sera précisé ci-après, présentera en solution dans l'eau un pKa inférieur à 6,3. En particulier, le CO2 n'est pas un acide au sens de la présente invention.For the purpose of the present invention, the term "acid compound" is intended to mean a compound which, in addition to what will be specified below, will have a pKa of less than 6.3 in solution in water. In particular, CO 2 is not an acid within the meaning of the present invention.

La réaction de déshydratation est effectuée par exemple sur des catalyseurs solides acides tels que ceux décrits dans le brevet français FR 2.882.052 .The dehydration reaction is carried out, for example, on acidic solid catalysts such as those described in the French patent. FR 2,882,052 .

Les catalyseurs qui conviennent sont des matériaux homogènes ou multiphases, insolubles dans le milieu réactionnel qui ont une acidité de Hammett, notée H0 inférieure à +2. Comme indiqué dans le brevet US 5,387,720 qui fait référence à l'article de K. Tanabe et al dans "Studies in Surface Science and Catalysis", Vol 51, 1989, chap 1 et 2 , l'acidité de Hammett est déterminée par titration amine à l'aide d'indicateurs ou par adsorption d'une base en phase gazeuse. Les catalyseurs répondant au critère d'acidité H0 inférieur à +2, peuvent être choisis parmi des matériaux siliceux naturels ou de synthèse ou les zéolithes acides ; des supports minéraux, tels que des oxydes, recouverts par des acides inorganiques, mono, di, tri ou polyacides ; des oxydes ou oxydes mixtes, des phosphates de fer ou encore des hétéropolyacides.Suitable catalysts are homogeneous or multiphase materials which are insoluble in the reaction medium and which have a Hammett acidity, denoted H 0 of less than +2. As stated in the patent US5,387,720 which refers to the article of K. Tanabe et al in "Studies in Surface Science and Catalysis", Vol 51, 1989, Chapters 1 and 2 , the acidity of Hammett is determined by amine titration using indicators or by adsorption of a base in the gas phase. The catalysts meeting the acidity criterion H 0 of less than +2 may be chosen from natural or synthetic siliceous materials or acidic zeolites; inorganic carriers, such as oxides, coated with inorganic acids, mono, di, tri or polyacids; oxides or mixed oxides, iron phosphates or heteropolyacids.

Avantageusement, les catalyseurs sont choisis parmi les zéolithes, les composites Nafion® (à base d'acide sulfonique de polymères fluorés), les alumines chlorées, les acides et sels d'acides phospho ou silico-tungstiques et/ou silicotungstiques, et différents solides de type oxydes métalliques tels que oxyde de tantale Ta2O5, oxyde de niobium Nb2O5, alumine Al2O3, oxyde de titane TiO2, zircone ZrO2, oxyde d'étain SnO2, silice SiO2 ou silicoaluminate SiO2Al2O3, imprégnés de fonctions acides telles que borate BO3, sulfate SO4, tungstate WO3, phosphate PO4, silicate SiO2, ou molybdate MoO3. Selon les données de la littérature, ces catalyseurs ont tous une acidité de Hammett H0 inférieure à +2.Advantageously, the catalysts are chosen from zeolites, Nafion® composites (acid-based sulfonic fluorinated polymers), chlorinated aluminas, phospho or silico-tungstic and / or silicotungstic acids and salts, and various metal oxide solids such as tantalum oxide Ta 2 O 5 , niobium oxide Nb 2 O 5 , alumina Al 2 O 3 , titanium oxide TiO 2 , zirconia ZrO 2 , tin oxide SnO 2 , silica SiO 2 or silicoaluminate SiO 2 Al 2 O 3 , impregnated with acidic functions such as borate BO 3 , sulfate SO 4 , WO 3 tungstate, PO 4 phosphate, SiO 2 silicate, or MoO 3 molybdate. According to the data of the literature, these catalysts all have a Hammett acidity H 0 of less than +2.

Les catalyseurs préférés sont les zircones sulfatées, les zircones phosphatées, les zircones tungstées, les zircones silicées, les oxydes de titane ou d'étain sulfatés, les alumines ou silices phosphatées, les phosphates de fer dopés, les sels d'acide phospho ou silico-tungstiques.The preferred catalysts are sulphated zirconias, zirconium phosphates, tungsten zirconias, silicified zirconias, sulphated titanium or tin oxides, phosphated aluminas or silicas, doped iron phosphates, phospho or silico acid salts. -tungstiques.

Ces catalyseurs ont tous une acidité de Hammett H0 inférieure à +2, l'acidité H0 peut alors varier dans une large mesure, jusqu'à des valeurs pouvant atteindre -20 dans l'échelle de référence avec les indicateurs de Hammett. Le tableau donné à la page 71 de la publication sur la catalyse acido-basique (C. Marcilly) Vol 1 aux Editions Technip (n°ISBN 2-7108-0841-2 ) illustre des exemples de catalyseurs solides dans cette gamme d'acidité.These catalysts all have a Hammett acidity H 0 of less than +2, the acidity H 0 can then vary to a large extent, up to values up to -20 in the reference scale with the Hammett indicators. The table given to the page 71 of the publication on acid-base catalysis (C. Marcilly) Vol 1 at Technip Editions (No. ISBN 2-7108-0841-2 ) illustrates examples of solid catalysts in this range of acidity.

Les catalyseurs sélectionnés pour cette réaction sont des solides acides. L'acidité des solides peut être mesurée de nombreuses façons et la méthode de Hammett n'est que l'une d'entre elles.The catalysts selected for this reaction are acidic solids. The acidity of solids can be measured in many ways and Hammett's method is just one of them.

L'ouvrage de C. Marcilly référencé ci-dessus liste par ailleurs différentes méthodes de mesure de l'acidité et de la basicité des solides.The work of C. Marcilly referenced above also lists various methods for measuring the acidity and basicity of solids.

On citera les publications de Aline Auroux où sont décrites différentes méthodes de mesure des échelles d'acidité des solides telles que : A. Auroux et A. Gervasini, « J. Microcalorimetric Study of the Acidity and Basicity of Metal Oxide Surfaces » Phys. Chem., (1990) 94, 6371-79 et L. Damjanovic et A. Auroux, dans « Handbook of Thermal Analysis and Calorimetry », Vol 5, Chapter 11 pages 387-485 : Recent Advances, Techniques and Applications, M.E. Brown et P.K. Gallager, editors (2008 Elsevier B.V. ).Aline Auroux's publications describe different methods of measuring solids acidity scales such as: A. Auroux and A. Gervasini, "J. Microcalorimetric Study of the Acidity and Basicity of Metal Oxide Surfaces" Phys. Chem., (1990) 94, 6371-79 and L. Damjanovic and A. Auroux, in Handbook of Thermal Analysis and Calorimetry, Vol 5, Chapter 11 pages 387-485: Recent Advances, Techniques and Applications, ME Brown and PK Gallager, editors (2008 Elsevier BV ).

Des méthodes utilisées pour mesurer cette acidité sont décrites dans les brevets EP 1 714 696 [0038et 0039] et EP 1 714 955 [0045et 0046] où l'on distingue les cas où le solide est de couleur blanche ou non.Methods used to measure this acidity are described in the patents EP 1 714 696 [0038and 0039] and EP 1 714 955 [0045 and 0046] where we distinguish cases where the solid is white or not.

Ces travaux illustrent notamment qu'un solide est rarement constitué soit de sites uniquement acides, soit de sites uniquement basiques. Les solides acides ont la plupart du temps à la fois des sites acides, majoritaires, mais aussi certains sites basiques. Cette dichotomie est particulièrement illustrée dans l'article de A. Auroux A. Gervasini à la page 6377 où la figure 13 montre qu'un même oxyde peut à la fois adsorber un composé acide tel que CO2 et un composé basique tel que NH3. Sans vouloir se lier à une quelconque théorie, on pense que ces derniers contribuent à la formation des sous produits dans le procédé.In particular, this work illustrates that a solid is rarely constituted either by only acid sites or only basic sites. The acidic solids have most of the time both acid sites, majority, but also some basic sites. This dichotomy is particularly illustrated in the article by A. Auroux A. Gervasini on page 6377 where Figure 13 shows that the same oxide can both adsorb an acid compound such as CO 2 and a basic compound such as NH 3 . Without wishing to be bound by any theory, it is thought that these contribute to the formation of by-products in the process.

Le procédé est mis en oeuvre en présence d'un composé acide présent dans la phase gazeuse du milieu réactionnel et qui présente une affinité avec les sites indésirables basiques constituant le catalyseur. Ce composé sera choisi parmi les acides durs et mous tels qu'ils sont définis dans la classification dite de Pearson illustrée dans les articles suivants : R.G. Pearson, J. Am. Chem. Soc., 85, 3533 (1963 ) ; R.G. Pearson, Science, 151 (1966)172 ; R.G. Pearson, Chemistry in Britain, March 1967, 103 ; R.G. Pearson, J. Chemical Education, Vol45 N°9 (1968) 581 et Vol 45 N°10 (1968) 643 ; R.G. Parr and R.G. Pearson, J. Am. Chem. Soc, (1983) 105, 7512 .The process is carried out in the presence of an acidic compound present in the gaseous phase of the reaction medium and which has an affinity with the basic undesirable sites constituting the catalyst. This compound will be selected from hard and soft acids as defined in the so-called Pearson classification. in the following articles: RG Pearson, J. Am. Chem. Soc., 85, 3533 (1963) ); RG Pearson, Science, 151 (1966) 172 ; RG Pearson, Chemistry in Britain, March 1967, 103 ; RG Pearson, J. Chemical Education, Vol 45 No. 9 (1968) 581 and Vol 45 No. 10 (1968) 643 ; RG Parr and RG Pearson, J. Am. Chem. Soc., (1983) 105, 7512 .

Il faut souligner que dans l'ouvrage de C Marcilly référencé plus haut aux pages 34 et suivantes est utilisée l'échelle fondée sur la théorie de Pearson.It should be pointed out that in Marcilly's book, referenced above on pages 34 and following, the scale based on Pearson's theory is used.

Ces composés peuvent être gazeux aux conditions normales mais ils peuvent être soit liquides ou même solides s'ils sont susceptibles de passer, dans les conditions opératoires du procédé, dans la phase gazeuse du milieu réactionnel.These compounds can be gaseous under normal conditions but they can be either liquid or even solid if they are likely to pass, under the operating conditions of the process, into the gaseous phase of the reaction medium.

De préférence, la déshydratation est conduite en présence d'une phase gazeuse contenant une fraction mineure d'au moins un composé acide au sens de la classification de PearsonPreferably, the dehydration is conducted in the presence of a gaseous phase containing a minor fraction of at least one acid compound as defined by Pearson's classification.

Ce composé acide sera choisi notamment parmi SO3, SO2, NO2, etc... On ne sortirait pas du cadre de l'invention, si l'on utilise un mélange de ces composés. Selon la théorie de Pearson les acides durs préfèrent s'associer aux bases dures et les acides mous aux bases moles. On peut utiliser un mélange de composés combinant différentes acidités afin d'inhiber les différents sites basiques présents sur le catalyseur.This acidic compound will be chosen especially from SO 3 , SO 2 , NO 2 , etc. It would not be outside the scope of the invention, if a mixture of these compounds is used. According to Pearson's theory hard acids prefer to associate with hard bases and soft acids with moles. A mixture of compounds combining different acidities can be used to inhibit the various basic sites present on the catalyst.

La teneur en composés acides dépendra de la nature du catalyseur choisi pour la réaction de déshydratation. Elle sera généralement comprise entre 1 et 3000 ppm de la phase gazeuse ou exprimée en pourcentages volumiques de 0.0001 à 0.3 %.The content of acidic compounds will depend on the nature of the catalyst chosen for the dehydration reaction. It will generally be between 1 and 3000 ppm of the gaseous phase or expressed in percentages by volume of 0.0001 to 0.3%.

Si la réaction est effectuée en phase liquide, le composé acide peut être sous forme liquide ou même solide dès lors qu'il est susceptible dans les conditions réactionnelles de passer en phase liquide pour atteindre les teneurs ci-dessus ou, en cas de composé solide, de se solubiliser puis de passer en phase liquide ainsi que cela a été précisé ci-dessus.If the reaction is carried out in the liquid phase, the acidic compound may be in liquid or even solid form if it is capable under reaction conditions of passing into the liquid phase to reach the above contents or, in the case of a solid compound , solubilize and then move to the liquid phase as has been specified above.

Il est à noter que le brevet EP 1 253 132 décrit l'utilisation dans un procédé de synthèse de l'acide acrylique par oxydation d'alcanes ou d'acroléine en présence d'un composé réducteur constitué par des acides organiques (acide formique ou oxalique) ou des composés contenant du soufre tels que SO2 ou H2S, SO2 étant préféré. Cependant on peut souligner qu'il ne s'agit pas de la même réaction avec un catalyseur différent et que l'activité dudit composé est de stabiliser le catalyseur et non pas d'augmenter sa sélectivité. La réaction selon l'invention peut être mise en oeuvre en phase gaz ou en phase liquide, de préférence en phase gaz.It should be noted that the patent EP 1 253 132 discloses the use in a process for synthesizing acrylic acid by oxidation of alkanes or acrolein in the presence of a reducing compound consisting of organic acids (formic or oxalic acid) or compounds containing sulfur such as SO 2 or H 2 S, SO 2 being preferred. However, it may be emphasized that it is not the same reaction with a different catalyst and that the activity of said compound is to stabilize the catalyst and not to increase its selectivity. The reaction according to the invention can be carried out in the gas phase or in the liquid phase, preferably in the gas phase.

Lorsque la réaction est réalisée en phase gaz, différentes technologies de procédé peuvent être utilisées, à savoir procédé en lit fixe, procédé en lit fluidisé ou procédé en lit fluidisé circulant. Dans les 2 premiers procédés, en lit fixe ou en lit fluidisé, la régénération du catalyseur peut être séparée de la réaction.When the reaction is carried out in the gas phase, various process technologies can be used, namely fixed bed process, fluidized bed process or circulating fluidized bed process. In the first two processes, in a fixed bed or in a fluidized bed, the regeneration of the catalyst can be separated from the reaction.

Elle peut se faire ex-situ, par exemple par extraction du catalyseur et combustion sous air ou avec un mélange gazeux contenant de l'oxygène moléculaire. Dans ce cas, la température et la pression auxquelles est opérée la régénération n'ont pas besoin d'être les mêmes que celles auxquelles est effectuée la réaction. De préférence l'ajout des composés acides au sens de Pearson, est effectué au niveau du Réacteur et non au cours de la régénération.It can be ex situ, for example by extraction of the catalyst and combustion in air or with a gaseous mixture containing molecular oxygen. In this case, the temperature and pressure at which the regeneration is effected need not be the same as those at which the reaction is carried out. Preferably the addition of the acidic compounds in the sense of Pearson, is performed at the Reactor and not during the regeneration.

Selon le procédé de l'invention, elle peut se faire en continu in-situ, en même temps que la réaction compte tenu de la présence d'une faible quantité d'oxygène moléculaire ou d'un gaz contenant de l'oxygène moléculaire dans le réacteur. Dans ce cas, la régénération s'apparente à une inhibition de la désactivation et se fait à la température et à la pression de la réaction. Du fait de ces conditions particulières où la régénération a lieu en continu, l'injection du composé acide gazeux se trouve être simultanée et de préférence en amont du lit catalytique de sorte que les composés acides soient parfaitement mélangés dans le mélange réactionnel.According to the process of the invention, it can be carried out continuously in situ, at the same time as the reaction taking into account the presence of a small amount of molecular oxygen or a gas containing molecular oxygen in the reactor. In this case, the regeneration is similar to an inhibition of the deactivation and is done at the temperature and pressure of the reaction. Because of these particular conditions where the regeneration takes place continuously, the injection of the gaseous acid compound is found to be simultaneous and preferably upstream of the catalytic bed so that the acidic compounds are perfectly mixed in the reaction mixture.

Dans le procédé à lit fluidisé circulant, le catalyseur circule dans deux capacités, un réacteur et un régénérateur. On sait que la réaction de déshydratation est endothermique, il faut donc apporter de l'énergie à la première capacité, alors que la régénération consistant en la combustion du coke est exothermique, il faut donc extraire des calories de la deuxième capacité. Dans le cas du lit fluidisé circulant, les deux systèmes peuvent se compenser : selon le procédé de l'invention, la régénération du catalyseur sous flux d'oxygène par combustion conduit à un réchauffement du catalyseur et par conséquent fournit l'énergie nécessaire pour la réaction de déshydratation lorsque le catalyseur réchauffé retourne dans le réacteur. Le temps de séjour dans chaque capacité dépend de la vitesse de désactivation du catalyseur et du taux de coke formé sur le catalyseur. En effet, un taux de coke minimal est souhaitable pour pouvoir ramener le solide à la bonne température, et un taux de coke maximal est nécessaire pour éviter de dégrader le solide par frittage lors de la combustion. L'injection du composé acide gazeux est de préférence effectuée au Réacteur.In the circulating fluidized bed process, the catalyst circulates in two capacities, a reactor and a regenerator. It is known that the dehydration reaction is endothermic, so it is necessary to bring energy to the first capacity, while the regeneration consisting of the combustion of the coke is exothermic, it is necessary to extract calories from the second capacity. In the case of the circulating fluidized bed, the two systems can be compensated: according to the process of the invention, the regeneration of the catalyst under an oxygen flow by combustion leads to a heating of the catalyst and consequently provides the energy necessary for the dehydration reaction when the heated catalyst returns to the reactor. The residence time in each capacity depends on the deactivation rate of the catalyst and the coke rate formed on the catalyst. Indeed, a minimum coke rate is desirable to bring the solid back to the correct temperature, and a maximum coke rate is necessary to avoid degrading the solid by sintering during combustion. The injection of the gaseous acid compound is preferably carried out at the reactor.

La réaction de déshydratation est effectuée en phase gaz en présence d'un catalyseur à une température allant de 150°C à 500°C, de préférence comprise entre 250°C et 350°C, et une pression comprise entre 1 et 5 bars. Lorsque la réaction est effectuée en phase liquide en présence d'un catalyseur à une température allant de 150°C à 500°C, de préférence comprise entre 250°C et 350°C, et une pression supérieure à 5 bars et de préférence comprise entre 20 et 80 bars.The dehydration reaction is carried out in the gas phase in the presence of a catalyst at a temperature ranging from 150 ° C. to 500 ° C., preferably between 250 ° C. and 350 ° C., and a pressure of between 1 and 5 bar. When the reaction is carried out in the liquid phase in the presence of a catalyst at a temperature ranging from 150 ° C. to 500 ° C., preferably between 250 ° C. and 350 ° C., and a pressure greater than 5 bar and preferably comprised between between 20 and 80 bars.

Les exemples suivants illustrent le procédé de la présente inventionThe following examples illustrate the process of the present invention

Lors de la déshydratation du glycérol en présence d'un catalyseur acide classique on obtient de l'acroléine mais aussi des sous-produits, tels que l'hydroxypropanone, le propanaldéhyde, l'acétaldéhyde, l'acétone, le phénol, les produits d'addition de l'acroléine sur le glycérol, les produits de polycondensation du glycérol, des éthers de glycérol cycliques ou non.When dehydrating glycerol in the presence of a conventional acidic catalyst is obtained acrolein but also by-products, such as hydroxypropanone, propanaldehyde, acetaldehyde, acetone, phenol, the products of addition of acrolein to glycerol, polycondensation products of glycerol, cyclic or non-cyclic glycerol ethers.

Ces exemples vont illustrer l'incidence de la présence du composé acide sur la sélectivité de la réaction au regard des divers sous-produits connus et notamment de l'hydroxypropanone qui est le composé le plus présent et est donc représentatif de l'efficacité du procédé. Ils illustreront également l'incidence de la présence de composés acide sur la désactivation du catalyseur.These examples will illustrate the impact of the presence of the acidic compound on the selectivity of the reaction with regard to the various known by-products and in particular of the hydroxypropanone which is the most present compound and is therefore representative of the efficiency of the process . They will also illustrate the impact of the presence of acid compounds on the deactivation of the catalyst.

Exemple 1 :Example 1

La réaction peut être conduite dans les conditions suivantes. On utilise un réacteur en pyrex contenant un lit de catalyseur retenu par un fritté. On charge tout d'abord un catalyseur tel que le catalyseur de déshydratation Zircone Tungstée de DaiIchi Kigenso KK, de référence Z1044 ayant une masse de 6,6 g environ et réduit à une granulométrie de 0,1-0,15 mm dilué avec 7 ml de carbure de silicium de fine granulométrie (0,125 mm). Ensuite on charge, une série de lits de carbure de silicium de granulométries différentes : 2ml en 0,125 mm , 7 ml en 0,5 mm et enfin 1,19 mm jusqu'en haut du réacteur.The reaction can be conducted under the following conditions. A Pyrex reactor containing a sintered catalyst bed is used. A catalyst such as the dehydration catalyst Zirconia Tungstea from Daiichi Kigenso KK, reference Z1044 having a mass of about 6.6 g and reduced to a particle size of 0.1-0.15 mm diluted with ml of fine grain silicon carbide (0.125 mm). Then we load a series of silicon carbide beds of different grain sizes: 2ml in 0.125 mm, 7 ml in 0.5 mm and finally 1.19 mm to the top of the reactor.

Le réacteur est ensuite placé dans un four connecté à l'installation de test. La température du catalyseur est régulée en température à 305 °C mesurée au niveau de la « couche de déshydratation ».The reactor is then placed in an oven connected to the test facility. The temperature of the catalyst is regulated in temperature at 305 ° C. measured at the level of the "dehydration layer".

Le réacteur est alimenté par le haut par un mélange gazeux de Hélium-Krypton / SO2 / Eau-Glycérol à une pression de 1,3 bar absolus. Le mélange gazeux Hélium-Krypton contient 4,92 % de Krypton qui sert d'étalon interne. Le mélange eau-glycérol contient 30 % en poids de glycérol.The reactor is fed from above by a gaseous mixture of Helium-Krypton / SO 2 / Water-Glycerol at a pressure of 1.3 bar absolute. The Helium-Krypton gas mixture contains 4.92% Krypton which serves as internal standard. The water-glycerol mixture contains 30% by weight of glycerol.

La constitution du mélange injecté est la suivante exprimée en pourcentage molaire :

  • Hélium/Krypton/O2/SO2/ Eau/Glycérol : 50 / 2,6 / 3,4 / 0,02 / 40,6 / 3,4.
The constitution of the injected mixture is the following expressed in molar percentage:
  • Helium / Krypton / O 2 / SO 2 / Water / Glycerol: 50 / 2.6 / 3.4 / 0.02 / 40.6 / 3.4.

Le débit d'introduction du mélange de charge est tel que la vitesse volumique horaire (VVH) sera de 2 000 h-1. . La vitesse volumique horaire est égale au ratio du débit gazeux total du mélange gazeux exprimé en normaux litres par heure par le volume apparent de catalyseur exprimé en litres.The rate of introduction of the charge mixture is such that the hourly volume velocity (VVH) will be 2,000 h -1 . . The hourly space velocity is equal to the ratio of the total gas flow rate of the gas mixture expressed in normal liters per hour by the apparent volume of catalyst expressed in liters.

Les effluents sont piégés dans l'eau en sortie du réacteur par un piège refroidi à 0°C permettant de séparer les effluents liquides des incondensables. L'acroléine et l'hydroxypropanone, comme composé modèle des sous produits autre que l'acide acrylique, sont dosés par analyse chromatographique.The effluents are trapped in the water leaving the reactor by a trap cooled to 0 ° C to separate the liquid effluents incondensables. Acrolein and hydroxypropanone, as the model compound of byproducts other than acrylic acid, are determined by chromatographic analysis.

Les effluents sont cumulés dans le piège pendant une durée de 60 minutes. Les gaz non condensables sont analysés pendant la durée du bilan. Le rendement en acroléine produite est de 70 mole %, et en acide acrylique de 2 mole % et en hydroxyacétone de 0,5 mole %.The effluents are accumulated in the trap for a period of 60 minutes. Non-condensable gases are analyzed during the balance sheet. The yield of acrolein produced is 70 mol%, and acrylic acid 2 mol% and hydroxyacetone 0.5 mol%.

Exemple 2 (Comparatif)Example 2 (Comparative)

On reproduira l'exemple 1, mais en absence de SO2.Example 1 will be repeated, but in the absence of SO 2 .

Les effluents sont cumulés dans le piège pendant une durée de 60 minutes . Les gaz non condensables sont analysés pendant la durée du bilan. Le rendement en acroléine produite est de 68 mole %, et en acide acrylique de 2 mole % et en hydroxyacétone de 2 mole %.The effluents are accumulated in the trap for a period of 60 minutes. Non-condensable gases are analyzed during the balance sheet. The yield of acrolein produced is 68 mol%, and acrylic acid 2 mol% and hydroxyacetone 2 mol%.

Exemple 3 :Example 3

On utilise le même réacteur en pyrex qu'à l'exemple 1. Il est chargé avec un catalyseur de déshydratation zircone tungstée de Daiichi Kigenso Kagaku Kogyo de référence Z1044 ring, broyé et tamisé à une granulométrie de 0,32-0,50 mm, de volume 7 ml et masse 9,18 g. Le catalyseur non dilué est placé entre 2 couches de carbure de silicium.The same Pyrex reactor is used as in Example 1. It is charged with a zirconia tungsten dehydration catalyst of Daiichi Kigenso Kagaku Kogyo reference Z1044 ring, crushed and sieved to a particle size of 0.32-0.50 mm. of volume 7 ml and mass 9.18 g. The undiluted catalyst is placed between two layers of silicon carbide.

Le réacteur est placé dans un four qui est régulé à une température de 275°C. Le réacteur est alimenté par un mélange gazeux à 275°C de N2/O2/SO2/eau/glycérol à une pression de 1,3 bar absolus. Ce mélange gazeux est obtenu en injectant dans un vaporiseur électrique d'une part un courant d'azote et un courant d'oxygène contrôlés en débit par des régulateurs de débit massique et d'autre part un flux liquide d'un mélange glycérol (Prolabo), eau déminéralisée et acide sulfureux à 7,4% SO2 (Sigma-Aldrich) par une pompe volumétrique de type HPLC et dont le débit est contrôlé par une balance.The reactor is placed in an oven which is regulated at a temperature of 275 ° C. The reactor is powered by a gaseous mixture at 275 ° C N 2 / O 2 / SO 2 / water / glycerol at a pressure of 1.3 bar absolute. This gaseous mixture is obtained by injecting into an electric vaporizer, on the one hand, a current of nitrogen and a stream of oxygen controlled in flow by mass flow controllers and, on the other hand, a liquid flow of a glycerol mixture (Prolabo ), demineralized water and 7.4% SO 2 (Sigma-Aldrich) sulphurous acid by an HPLC type volumetric pump whose flow is controlled by a balance.

La constitution du mélange injecté est la suivante exprimée en pourcentages molaires :

  • N2/O2/SO2/eau/glycérol : 15,4/3,9/0,005/74,5/6,2.
The constitution of the injected mixture is the following expressed in molar percentages:
  • N 2 / O 2 / SO 2 / water / glycerol: 15.4 / 3.9 / 0.005 / 74.5 / 6.2.

Le débit d'introduction du mélange de charge est tel que la vitesse volumique horaire (VVH) est de 4 200 h-1 The charge introduction rate of the charge mixture is such that the hourly volume velocity (VVH) is 4,200 h -1

Après 3 heures d'injection du mélange gazeux sur le catalyseur, on réalise un bilan matière pendant 90 minutes de la même façon qu'à l'exemple 1. Les résultats sont reportés au tableau 1.After 3 hours of injection of the gaseous mixture onto the catalyst, a material balance is carried out for 90 minutes in the same manner as in Example 1. The results are reported in Table 1.

Exemple 4 :Example 4

Les conditions de l'exemple 3 sont reproduites avec un mélange gazeux de composition molaire :

  • N2/O2/SO2/eau/glycérol : 15,4/3,9/0,025/74,5/6,2.
The conditions of Example 3 are reproduced with a gaseous mixture of molar composition:
  • N 2 / O 2 / SO 2 / water / glycerol: 15.4 / 3.9 / 0.025 / 74.5 / 6.2.

On réalise un bilan après 3 heures et après 24 heures d'injection du mélange.A balance is made after 3 hours and after 24 hours of injection of the mixture.

Les résultats sont reportés au tableau 1.The results are reported in Table 1.

Exemple 5 (Comparatif)Example 5 (Comparative)

Les conditions de l'exemple 3 sont reproduites avec un mélange gazeux de composition molaire :

  • N2/O2/SO2/eau/glycérol : 15,4/3,9/ 0 /74,5/6,2.
The conditions of Example 3 are reproduced with a gaseous mixture of molar composition:
  • N 2 / O 2 / SO 2 / water / glycerol: 15.4 / 3.9 / 0 / 74.5 / 6.2.

On réalise un bilan après 3 heures et 24 heures.A balance is made after 3 hours and 24 hours.

Les résultats sont reportés au tableau 1. Tableau 1 Exemple 3 4 5 (comparatif) Durée d'injection (h) 3 3 24 3 24 SO2 (mol %) 0,005 0,025 0,025 0 0 Conversion glycérol (%) 100 100 87 100 69 Rendement acroléine (%) 73 73 60 72 49 Rendement hydroxypropanone (%) 0, 4 0,2 5, 9 2,4 5, 9 The results are reported in Table 1. <u> Table 1 </ u> Example 3 4 5 (comparative) Injection time (h) 3 3 24 3 24 SO 2 (mol%) 0.005 0,025 0,025 0 0 Glycerol conversion (%) 100 100 87 100 69 Acrolein yield (%) 73 73 60 72 49 Yield hydroxypropanone (%) 0, 4 0.2 5, 9 2.4 5, 9

On constate que l'ajout de SO2 induit non seulement une amélioration du rendement, mais également limite la désactivation du catalyseur.It is found that the addition of SO 2 induces not only an improvement of the yield, but also limits the deactivation of the catalyst.

Claims (5)

  1. A process for the synthesis of acrolein by dehydration of glycerol in the presence of a solid acid catalyst having a Hammett acidity of less than +2, characterized in that it is implemented in a reaction medium comprising a gas phase comprising a content between 1 and 3000 ppm of at least one acid compound within the meaning of the Person classification chosen from SO3, SO2 or NO2.
  2. The process as claimed in claim 1, characterized in that the catalyst is chosen from zeolites, Nafion® composites, chlorinated aluminas, phosphotungstic and/or silicotungstic acids and acid salts, and solids of the type comprising metal oxides, such as tantalum oxide Ta2O5, niobium oxide Nb2O5, alumina Al2O3, titanium oxide TiO2, zirconia ZrO2, tin oxide SnO2, silica SiO2 or silicoaluminate SiO2/Al2O3, impregnated with acid functional groups, such as borate BO3, sulfate SO4, tungstate WO3, phosphate PO4, silicate SiO2 or molybdate MoO3.
  3. The process as claimed in claim 1 or claim 2, characterized in that the catalyst is chosen from sulfated zirconias, phosphated zirconias, tungstated zirconias, silica zirconias, sulfated titanium or tin oxides, phosphated aluminas or silica, doped iron phosphates, or phosphor- or silicotungstic acid salts.
  4. The process as claimed in one of claims 1 to 3, characterized in that the dehydration reaction is carried out in the gas phase at a temperature of between 150°C and 500°C, preferably of between 250°C and 350°C, and under a pressure of between 1 and 5 bar.
  5. The process as claimed in one of claims 1 to 3, characterized in that the reaction is carried out in the liquid phase at a temperature of between 150°C and 500°C, preferably of between 250°C and 350°C, and under a pressure of greater than 5 bar and preferably of between 20 and 80 bar.
EP09769505.0A 2008-06-03 2009-05-29 Method for producing acrolein by means of dehydration of glycerol Not-in-force EP2280919B1 (en)

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FR0853668A FR2931820B1 (en) 2008-06-03 2008-06-03 PROCESS FOR THE PRODUCTION OF ACROLEIN BY DEHYDRATION OF GLYCEROL
PCT/FR2009/051019 WO2009156664A2 (en) 2008-06-03 2009-05-29 Method for producing acrolein by means of dehydration of glycerol

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US9234064B2 (en) * 2011-05-11 2016-01-12 Archer Daniels Midland Company Processes for making acrylic-type monomers and products made therefrom
KR20150055402A (en) * 2013-11-13 2015-05-21 주식회사 엘지화학 Method of preparing catalyst for dehydration of glycerin, and preparing method of acrolein
KR101629003B1 (en) * 2013-11-18 2016-06-09 주식회사 엘지화학 Catalyst for dehydration of glycerin, method of preparing the same, and preparing method of acrolein
US9796648B2 (en) 2014-05-02 2017-10-24 University Of Tennessee Research Foundation Glycerol dehydration methods and products thereof
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CN106008188B (en) * 2016-05-30 2018-05-29 浙江工业大学 A kind of glycerin catalytic dehydration prepares the new method of methacrylaldehyde
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